System and method for automated processing of bulk containers

ABSTRACT

A system and method is used to automatically process the contents of a containers. The contents may be bulk materials used by a business or organization. The container enters the system via a tow assembly mechanism, a grasping mechanism clasps the container, a lid secures the contents, the container is lifted and rotated to allow the contents of the container to exit the container.

DESCRIPTION RELATED APPLICATION

[0001] The present application is related to and claims the priority ofU.S. Provisional Application No. 60/287,022 filed Apr. 30, 2001, in thename of Carl SMITH, and titled ADVANCED BULK AUTOMATED CONTAINERUNLOADING SYSTEM, the entire contents of which are fully incorporatedherein by reference.

TECHNICAL FIELD

[0002] This invention relates generally to the automated processing oflarge containers of bulk material.

BACKGROUND

[0003] In industry today, production, manufacturing, and distributionfacilities for any business utilize automated services to quickly andefficiently handle bulk materials. These bulk materials may includeanything from products sold by a company to bulk mail sent and receivedby businesses and other organizations. In the case of bulk mail, manybusinesses and organizations specializing in mail delivery have bulkmail facilities, which process and sort mail according to certain userdefined criteria (e.g., recipient's name, ZIP code, street address,etc.). These facilities can exist for any type of business. The purposeof having a facility designed for processing materials in bulk is toimprove the entire assembly line process of getting materials to andfrom the business or organization efficiently so that the consumer mayrealize a cost savings or receive a higher quality product or service.Handling materials in bulk is more efficient and cost effective thanhandling materials individually, and businesses and other organizationsconstantly seek to improve the steps in existing methods and systems tomake the entire process more efficient and cost-effective.

[0004] One step in processing bulk materials, for example, is theinitial step of receiving the incoming materials at the bulk materialprocessing facility. Current methods of transporting bulk materials, forexample unloading the contents of a truck onto a loading dock, may beslow and require too much human exertion to be cost effective andefficient. Furthermore, increased human intervention, even in automatedprocesses, in handling bulk materials increases the risk of harm toemployees or workers of the bulk material processing facility. Currentmethods of automated transporting of bulk materials are not userfriendly, may cause delays in the entire production, manufacturing, ordistribution process, and may have a high risk of harm to workers whenmanual attention is needed.

[0005] It is therefore desirable to provide systems and methods to allowfor the safe, efficient, cost effective, and automated transportation ofbulk materials to the facilities engaged in processing those bulkmaterials.

SUMMARY

[0006] There is provided a system for automatically processing contentsof a first container, comprising a system for automatically processingcontents of containers, comprising a tow assembly for advancing a firstcontainer to a first predetermined position; a grasping mechanism forsecurely clasping the first container at the first predeterminedposition; a lifting mechanism, coupled to the grasping mechanism, formoving the first container between the first predetermined position anda second predetermined position, and to begin rotating the container, atthe second predetermined position, to a third predetermined position;and a lid mechanism for covering the contents of the first container atthe first predetermined position and moving apart to allow the contentsto be released from the container at the third predetermined position.

[0007] There is also provided A method for automatically processingcontents of containers; comprising advancing a first container, in anupright position, along a path with a tow assembly mechanism; graspingthe first container at a first predetermined position; lifting thecontainer to a second predetermined position, while the contents aresecured inside the first container by a lid; rotating the firstcontainer to a third predetermined position and moving the lidsufficiently to allow the contents to exit from the first container;returning the first container, in the upright position, to the firstpredetermined position; and advancing the first container along the pathso that a second container may be processed.

[0008] Additional features and advantages will be set forth in part inthe description which follows, and in part will be obvious from thedescription, or may be learned by practice of the claims. The advantageswill be realized and attained by means of the elements and combinationsparticularly pointed out in the appended claims.

[0009] It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a flowchart of a method of processing a bulk container,consistent with the present invention;

[0011]FIG. 2 is a front view of a system for processing a bulkcontainer;

[0012]FIG. 3 is a cross sectional view of FIG. 2;

[0013]FIG. 4 is a front view of FIG. 2, showing a step involved inprocessing bulk containers;

[0014]FIG. 5 is a front view of FIG. 2, showing a step involved inprocessing bulk containers;

[0015]FIG. 6 is a front view of FIG. 2, showing a step involved inprocessing bulk containers; and

[0016]FIG. 7 is a front view of FIG. 2, showing a step involved inprocessing bulk containers.

DETAILED DESCRIPTION

[0017] Referring now to the drawings, in which the same referencenumbers will be used throughout the drawings to refer to the same orlike parts, FIG. 1 is a flowchart of a method for automaticallyprocessing bulk materials, for example, unloading a large and heavycontainer of packages. A method for processing bulk materials in acontainer begins at Stage 102, where a user places a container full ofpackages, using the example from above, in a position accessible to atow assembly, so that the tow assembly advances the container to apredetermined first position. The tow assembly may be a chain in thefloor which attaches to the container and pulls the container along atrack. The container may include a securing component, such as a net orlid, to prevent the contents from spilling from the container.

[0018] The predetermined first position is a user defined station wherethe container is placed in order to fulfill the other stages within themethod of processing materials in a bulk container. The firstpredetermined position can be inside a system or machine designed toimplement the stages described herein.

[0019] Once the container is at the first predetermined position, agrasping mechanism, such as a set of arms, securely grip the containerat Stage 104, so that the container is securely fastened within themechanism. The arms can be made of high pressured vulcanized rubber oranother suitable material to hold and handle the container.

[0020] Once the arms have securely gripped the container, the containeris lifted, at Stage 106, to a second predetermined position. The secondpredetermined position may be directly above the first predeterminedposition, so that the container is suspended at a height suitable forrotation about a horizontal axis.

[0021] At Stage 108, the lid is opened and the container is rotatedabout a horizontal axis to an angle to allow the contents of thecontainer. A suitable angle for this purpose may be approximately 155degrees from the initial orientation of the container at the secondpredetermined position. A guide may be used to ensure that the contentsare safely removed from the container without damage. In addition, thecontainer may be jostled or shaken, to allow trapped contents tounfasten and fall from the container.

[0022] Once the contents have been discharged from the container, thecontainer is rotated back to an upright position and returned to thefirst predetermined position at Stage 110. At Stage 112, the containeris advanced further along the track by the tow assembly and the methodis repeated for other containers that need to be processed in thismanner.

[0023]FIG. 2 is a front view of a system 200 for processing bulkcontainers, using, for example, the method outlined in FIG. 1. System200 may include a support structure 202 mounted on a platform 204, alifting mechanism 206, a track 208, pusher 210, container 212, and arepository 218. Container 212 may further include wheels 214 and a pin216. The contents of container 212 may constitute anything that needsprocessing under the method of FIG. 1, including bulk mail packages.

[0024] Lifting mechanism 206 may further include a guide 219, a lid 220,and clamps 222. FIG. 2 shows lifting mechanism 206 in an up position, aslifting mechanism 206 waits for container 212 to advance to the firstpredetermined position, which may be a position directly underneathlifting mechanism 206 on platform 204. Lifting mechanism 206 isdescribed in further detail below.

[0025] Container 212, using wheels 214, is moved onto platform 204 alongtrack 208. As container 212 advances to the first predeterminedposition, pin 216, which may be located on the bottom side of container212, engages a pusher 210, so that container 212 may be secured tofollow track 208.

[0026] System 200 may also include structures to guard against anoverflow of containers from entering. There may be a situation whereother containers to be processed precede container 212 in a processqueue. Container 212 may not be processed until all preceding containersare processed. This may be implemented by using an overflow limit switchin track 208 to prevent system 200 from accepting container 212 ifanother container is already being processed.

[0027]FIG. 3 shows system 200 in greater detail. In FIG. 3, container212 is inside system 200 and on top of platform 204. Pin 216, attachedto the bottom of container 212 engages pusher 210, so that container 212is secured to track 208. Pusher 210 advances container 212 to proceedalong track 208. A towline assembly may also be included in track 208.The towline assembly may include a chain attached to pusher 210 thatpulls container 212 into system 200 after pin 216 engages pusher 210,but may include anything capable or suitable to pull container 212.

[0028]FIGS. 4 through 7, front views of previously described system 200,show in greater detail the method outlined in FIG. 1. FIG. 4 is a frontview of system 200 using, for example, the method outlined in FIG. 1.FIG. 4 shows system 200 lowered over container 212 at the firstpredetermined position. After container 212 enters system 200, pin 216engages pusher 210, lifting mechanism 206 lowers over container 212 andlid 220 closes (or remains closed) to secure the contents of container212. The contents of container 212 may be packaged bulk mail, which isbeing transported to a conveyor belt or a storage bin.

[0029] Next, referring to FIG. 5, clamps 222 securely grasp container212 in preparation of lifting container 212. The position of container212, when still on platform 204, may be a user defined firstpredetermined position, as previously described.

[0030] Referring to FIG. 6, pusher 210 disengages pin 216 and liftingmechanism 206 lifts container 212 to a user defined second predeterminedposition. The second predetermined position can be above the firstpredetermined position to allow lifting mechanism 206 and container 212to rotate.

[0031] Next, in FIG. 7, lifting mechanism 206 rotates about an axisperpendicular to the plane of FIG. 7, in order to empty container 212.The lifting mechanism may rotate either way, but should rotate to anglethat allows the contents to safely fall from container 212. Once liftingmechanism 206 and container 212 have reached that angle, lid 220 isopened and the contents of container 212 fall into repository 218. Also,guide 219 may be used in guiding the contents of container 212 intorepository 218, to ensure all the contents reach repository 218 withoutdamaging the contents. Repository 218 may be any suitable device used inconjunction with transporting bulk materials (e.g., a bin, a loadingtruck, or a conveyor belt). Lifting mechanism 206 may also have sensorslocated on either side of the opening to container 212. This allowssystem 200 to sense whether the contents have all been removed fromcontainer 212. Lifting mechanism 206 may also jostle or shake container212 to loosen trapped contents. Once all the contents have been removedfrom container 212, lifting mechanism rotates back into the secondpredetermined position and then subsequently lowered to the firstpredetermined position (see FIG. 5). If sensors are used, liftingmechanism 206 can return to the first predetermined position after thesensors indicate that the flow of materials exiting container 212 hasended. At the second predetermined position, clamps 222 disengage fromcontainer 212 (FIG. 4) and lifting mechanism 206 raises to its upposition (see FIG. 3), leaving processed container 212 on platform 204.Pin 216 engages pusher 210 and container 212 is advanced out along track208.

[0032] Other embodiments will be apparent to those skilled in the artfrom consideration of the specification and practice of the appendedclaims disclosed herein. It is intended that the specification andexamples be considered as exemplary only, with a true scope and spiritbeing indicated by the following claims.

What is claimed is:
 1. A system for automatically processing contents ofcontainers, comprising: a tow assembly for advancing a first containerto a first predetermined position; a grasping mechanism for securelyclasping the first container at the first predetermined position; alifting mechanism, coupled to the grasping mechanism, for moving thefirst container between the first predetermined position and a secondpredetermined position, and to begin rotating the container, at thesecond predetermined position, to a third predetermined position; and alid mechanism for covering the contents of the first container at thefirst predetermined position and moving apart to allow the contents tobe released from the container at the third predetermined position. 2.The system of claim 1, further comprising a graphical interface fordisplaying a status condition of the first container.
 3. The system ofclaim 1, further comprising an overflow mechanism which prevents asecond container from entering the first predetermined position when thefirst container is being processed.
 4. The system of claim 1, furthercomprising sensors to indicate when the container is either at the firstpredetermined position, the second predetermined position, or the thirdpredetermined position.
 5. The system of claim 1, wherein the thirdpredetermined position is at an angle of approximately 155 degrees fromthe second predetermined position.
 6. The system of claim 1, wherein lidmechanism contains a sensor to monitor and detect the flow of thecontents exiting from the first container.
 7. The system of claim 1,wherein the lifting mechanism jostles the first container at the thirdpredetermined position to loosen the contents from the first container.8. The system of claim 1, comprising a first motor for lifting the firstcontainer, a for rotating the first container, and third motor to movethe lid mechanism.
 9. The system of claim 1, wherein the tow assemblyincludes a chain having a removable connection to the first containerand located in a track, the chain advancing the first container alongthe track.
 10. A method for automatically processing contents ofcontainers; comprising: advancing a first container, in an uprightposition, along a path with a tow assembly mechanism; grasping the firstcontainer at a first predetermined position; lifting the container to asecond predetermined position, while the contents are secured inside thefirst container by a lid; rotating the first container to a thirdpredetermined position and moving the lid sufficiently to allow thecontents to exit from the first container; returning the firstcontainer, in the upright position, to the first predetermined position;and advancing the first container along the path so that a secondcontainer may be processed.
 11. The method of claim 10, furthercomprising a graphical interface for displaying a status condition ofthe first container.
 12. The method of claim 10, further comprising anoverflow mechanism which prevents the second container from advancing tothe first predetermined position when the first container is beingprocessed.
 13. The method of claim 10, further comprising sensors toindicate when the first container is either at the first predeterminedposition, the second predetermined position, or the third predeterminedposition.
 14. The method of claim 10, wherein the third predeterminedposition is at an angle 155 degrees away from the second predeterminedposition.
 15. The method of claim 10, wherein lid mechanism contains asensor to monitor and detect the flow of the contents exiting the firstcontainer.
 16. The method of claim 10, wherein the lifting mechanismjostles the first container at the third predetermined position toloosen contents from the first container.